Inflatable Ball and Method of Making the Same

ABSTRACT

An inflatable ball includes an inflatable bladder and s skin layer. The skin layer covers the inflatable bladder, and includes a plurality of interconnected panel segments. At least one of the panel segments includes a panel substrate proximate to the inflatable bladder, and a transparent protective layer, which has an inner surface printed with a pattern and applied with a glue layer for attaching to the panel substrate.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention relates to an inflatable ball, more particularly to an inflatable ball which is formed with a pattern having a relatively large size and which has improved protection for the pattern. The invention also relates to a method of making the inflatable ball.

2. Description of the Related Art

Referring to FIGS. 1 and 2, a conventional method of forming a pattern 112 on an inflatable ball 11 includes the steps of:

I) disposing a release paper 12 printed with the pattern 112 on the ball 11 which has been inflated so that the pattern 112 is proximate to an outer surface 111 of the ball 11;

II) transfer printing the pattern 112 onto the outer surface of the ball 11 using a pressure cylinder 13 under a pressure of about 70 pb/in² at a temperature above 100° C.; and

III) removing the release paper 12 from the ball 11. However, the conventional method has the following shortcomings:

1) Since the pattern 112 is not covered with a protective layer, it is liable to be stained or worn out.

2) Since the transfer printing step is conducted directly on the ball 11, which has been inflated, under a high pressure and at an elevated temperature, the size of the pattern 112 which can be transfer printed is limited due to the curvature of the ball 11, and the pattern 112 transfer printed onto the ball 11 is liable to be wrinkled.

Another conventional method of forming an inflatable ball with a pattern involves an offset lithography technique. Since only a single color can be printed via each offset lithography procedure, which includes multiple steps, such as plating making, wetting, inking, offsetting, and printing, the offset lithography technique is relatively complicated and costly. Therefore, the use of the offset lithography technique is discouraged, especially when the quantity of the inflatable balls to be printed is small or when a plurality of different patterns are to be printed on each of the inflatable balls.

SUMMARY OF THE INVENTION

Therefore, an object of the present invention is to provide an inflatable ball which is formed with a pattern having a relatively large size and which has improved protection for the pattern.

Another object of the present invention is to provide a method of making the inflatable ball.

Accordingly, in a first aspect of the present invention, an inflatable ball includes an inflatable bladder and a skin layer. The skin layer covers the inflatable bladder, and includes a plurality of interconnected panel segments. At least one of the panel segments includes a panel substrate proximate to the inflatable bladder, and a transparent protective layer, which has an inner surface printed with a pattern and applied with a glue layer for attaching to the panel substrate.

In a second aspect of the present invention, a method of making an inflatable ball includes interconnecting a plurality of panel segments to form a skin layer covering an outer surface of an inflatable bladder. At least one of the panel segments is made by a panel forming method including the steps of: a) printing a pattern on one side of a substrate that is coated with a release agent layer; b) adhering a transparent protective layer to said one side of the substrate that is printed with the pattern; c) removing the substrate from the transparent protective layer so that the pattern is transfer-printed onto the transparent protective layer; d) applying a glue layer on the transparent protective layer so that the pattern is covered with the glue layer; and e) adhering the transparent protective layer to a panel substrate via the glue layer so that the pattern is disposed between the transparent protective layer and the panel substrate.

In a third aspect of this invention, an inflatable ball includes an inflatable bladder and a skin layer. The skin layer covers the inflatable bladder, and includes a plurality of interconnected panel segments. At least one of the panel segments is made by a panel forming method including the steps of: a) printing a pattern on one side of a substrate that is coated with a release agent layer; b) adhering a transparent protective layer to said one side of the substrate that is printed with the pattern; c) removing the substrate from the transparent protective layer so that the pattern is transfer-printed onto the transparent protective layer; d) applying a glue layer on the transparent protective layer so that the pattern is covered with the glue layer; and e) adhering the transparent protective layer to a panel substrate via the glue layer so that the pattern is disposed between the transparent protective layer and the panel substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiments with reference to the accompanying drawings, of which:

FIG. 1 is a flow chart of a conventional method of forming a pattern on an inflatable ball;

FIG. 2 illustrates consecutive steps of the conventional method;

FIG. 3 is a perspective view of a preferred embodiment of an inflatable ball according to this invention;

FIG. 4 is an exploded perspective view of a panel segment of the preferred embodiment;

5 FIG. 5 is a flow chart of a preferred embodiment of a method of making an inflatable ball according to this invention;

FIGS. 6-A and 6-B illustrate consecutive steps of the preferred embodiment of FIG. 5; and FIG. 7 is a view illustrating an adhering step of another preferred embodiment of a method of making an inflatable ball according to this invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before the present invention is described in greater detail, it should be noted that like elements are denoted by the same reference numerals throughout the disclosure.

Referring to FIGS. 3 and 4, a preferred embodiment of an inflatable ball according to this invention is shown to include an inflatable bladder 81 and a skin layer 82. The skin layer 82 covers the inflatable bladder 81, and includes a plurality of tailored panel segments 821 interconnected using any suitable manners well known in the art, such as sewing. One of the panel segments 821 includes a panel substrate 3 proximate to the inflatable bladder 81, and a transparent protective layer 5, which has an inner surface printed with a pattern 51 and applied with a glue layer 4 for attaching to the panel substrate 3. The inflatable ball may further include luminous powders 41 disposed between the transparent protective layer 5 and the glue layer 4.

In this embodiment, the panel substrate 3 is made of ethylene vinyl acetate copolymer, but should not be limited thereto. The transparent protective layer 5 is a hot melt adhesive layer 52, and the pattern 51 is an ink-based pattern printed on the hot melt adhesive layer 52. Preferably, the hot melt adhesive layer 52 is made of thermoplastic vulcanizate, polyvinyl chloride, or the like. The glue layer 4 is preferably an oil-based glue.

Referring to FIGS. 5, 6-A, and 6-B, the preferred embodiment of a method of making the inflatable ball according to this invention includes the steps of:

A) Coating a Release Agent Layer:

A release agent layer 702 is coated on one side of a substrate 701. In this preferred embodiment, the substrate 701 is made of polyester. Preferably, the release agent layer 702 is coated on the substrate 701 after the substrate 701 is treated with corona. Alternatively, the substrate 701 coated with the release agent layer 702 can be one obtained directly from a supplier.

B) Printing a Pattern:

A pattern 51 is printed on said one side of the substrate 701 that is coated with the release agent layer 702 using an inkjet printer 704 connected to a computer 703. The computer 703 is operable to cause the inkjet printer 704 to print the pattern 51 on the substrate 701.

C) Adhering a Transparent Protective Layer:

A transparent protective layer 5 is adhered to said one side of the substrate 701 that is printed with the pattern 51 by covering a hot melt adhesive sheet 705 on the substrate 701, and hot pressing the hot melt adhesive sheet 705 against the substrate 701 using two rollers 706 at a temperature of about 70-80° C. The hot melt adhesive sheet 705 is made of thermoplastic vulcanizate, polyvinyl chloride, or the like. Alternatively, this adhering step can be conducted using a laminating machine (not shown).

D) Removing the Substrate:

The substrate 701 is removed from the transparent protective layer 5 so that the pattern 51 is transfer-printed onto the transparent protective layer 5.

E). Spreading Luminous Powders:

Luminous powders 41 are spread on a surface of the transparent protective layer 5 that is printed with the pattern 51.

F) Applying a Glue Layer:

A glue layer 4 is applied on the transparent protective layer 5 so that the pattern 51 is covered with the glue layer 4.

G) Adhering the Transparent Protective Layer to a Panel Substrate:

The transparent protective layer 5 is adhered to a panel substrate 3 via the glue layer 4 to obtain a panel segment 821 in which the pattern 51 is disposed between the transparent protective layer 5 and the panel substrate 3.

H) Interconnecting Panel Segments:

The panel segment 821 and other panel segments 821 with or without the pattern 51 are tailored and interconnected, for example, via sewing, to form a skin layer 82 covering an outer surface of an inflatable bladder 81 so as to obtain the inflatable ball.

It should be noted herein that, since the feature of the present invention does not reside in the construction of the inflatable bladder 81, which is known in the art, details of the same are omitted herein for the sake of brevity.

Referring to FIGS. 5 and 7, another preferred embodiment of a method of making an inflatable ball according to this invention is similar to the aforesaid preferred embodiment except that the step C) is conducted by coating a molten hot-melt adhesive on a carrier plate 708 and adhering the carrier plate 708 to the substrate 701 via the hot-melt adhesive. In this preferred embodiment, the carrier plate 708 is a hot melt adhesive sheet. The hot-melt adhesive and the hot melt adhesive sheet are made of thermoplastic vulcanizate, polyvinyl chloride, or the like, and constitute the transparent protective layer 5.

In view of the aforesaid, the inflatable ball of this invention has the following advantages over the prior art:

1) Since the pattern 51 is covered with the hot melt adhesive layer 52, it can be protected from being stained or worn out.

2) Since the panel segment 821 formed with the pattern 51 is made prior to being interconnected to other panel segments 821 to form the skin layer 82 of the inflatable ball, the shortcomings of the prior art, such as the limited pattern size and the wrinkled pattern, can be avoided.

3) Since the pattern 51 is easily printed using the inkjet printer 704 and is transfer printed onto the transparent protective layer 5, the present invention is much simpler compared to the use of the offset lithography technique.

While the present invention has been described in connection with what are considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements. 

1. An inflatable ball, comprising: an inflatable bladder; and a skin layer covering said inflatable bladder, and including a plurality of interconnected panel segments, at least one of said panel segments including a panel substrate proximate to said inflatable bladder, and a transparent protective layer having an inner surface printed with a pattern and applied with a glue layer for attaching to said panel substrate.
 2. The inflatable ball as claimed in claim 1, wherein said transparent protective layer includes a hot melt adhesive layer, and said pattern is an ink-based pattern printed on said hot melt adhesive layer.
 3. The inflatable ball as claimed in claim 1, wherein said hot melt adhesive layer is made of a material selected from the group consisting of thermoplastic vulcanizate and polyvinyl chloride.
 4. The inflatable ball as claimed in claim 1, wherein said glue layer includes an oil-based glue.
 5. The inflatable ball as claimed in claim 1, further including luminous powders disposed between said transparent protective layer and said glue layer.
 6. The inflatable ball as claimed in claim 1, wherein said panel substrate is made of a material including ethylene-vinyl acetate copolymer.
 7. A method of making an inflatable ball, comprising interconnecting a plurality of panel segments to form a skin layer covering an outer surface of an inflatable bladder, wherein at least one of the panel segments is made by a panel forming method including the steps of: a) printing a pattern on one side of a substrate that is coated with a release agent layer;, b) adhering a transparent protective layer to said one side of the substrate that is printed with the pattern; c) removing the substrate from the transparent protective layer so that the pattern is transfer-printed onto the transparent protective layer; d) applying a glue layer on the transparent protective layer so that the pattern is covered with the glue layer; and e) adhering the transparent protective layer to a panel substrate via the glue layer so that the pattern is disposed between the transparent protective layer and the panel substrate.
 8. The method as claimed in claim 7, wherein the step b) is conducted by covering a hot melt adhesive sheet on the substrate, and hot pressing the hot melt adhesive sheet against the substrate.
 9. The method as claimed in claim 7, further comprising a step of spreading luminous powders on a surface of the transparent protective layer that is printed with the pattern prior to the step d).
 10. The method as claimed in claim 7, wherein the step b) is conducted by coating a hot-melt adhesive on a carrier plate and adhering the carrier plate to the substrate via the hot-melt adhesive.
 11. The method as claimed in claim 10, wherein the carrier plate is a hot melt adhesive sheet.
 12. The method as claimed in claim 7, wherein the step a) is conducting using an inkjet printer connected to a computer, the computer being operable to cause the inkjet printer to print the pattern on the substrate.
 13. An inflatable ball, comprising: an inflatable bladder; and a skin layer covering said inflatable bladder, and including a plurality of interconnected panel segments, at least one of said panel segments being made by a panel forming method including the steps of: a) printing a pattern on one side of a substrate that is coated with a release agent layer; b) adhering a transparent protective layer to said one side of said substrate that is printed with said pattern; c) removing said substrate from said transparent protective layer so that said pattern is transfer-printed onto said transparent protective layer; d) applying a glue layer on said transparent protective layer so that said pattern is covered with said glue layer; and e) adhering said transparent protective layer to a panel substrate via said glue layer so that said pattern is disposed between said transparent protective layer and said panel substrate. 